Method for producing a hybrid component, and pressing tool for producing a hybrid component

Abstract

The present invention discloses a method for producing a hybrid component (1) which comprises at least one plastics layer (2) and at least one protection element (4, 7) which is connected to the plastics layer (2), wherein the method comprises the following method steps: - providing a pressing tool (10) which comprises a lower tool part (20) and an upper tool part (30), wherein the upper tool part (30) and the lower tool part (20) are movable relative to one another along a movement direction (R) between an open position and a closed position of the pressing tool (10); - placing at least one protection element (4, 7) and at least one polymer melt (P) into the pressing tool, which is in the open position, in such a way that the polymer melt (P) and the protection element (4, 7) are arranged above one another along the movement direction (R); and - closing the pressing tool (10), with the result that the upper tool part (30) comes into contact at least indirectly with the at least one polymer melt (P) or with the at least one protection element (4, 7), and the polymer melt (P) is reshaped by way of application of pressure by means of the upper tool part (30) and / or by means of the lower tool part (20), and the at least one polymer melt (P) is connected to the at least one protection element (4, 7) with the formation of the plastics layer (2). Furthermore, the present invention discloses a pressing tool (10) for producing a hybrid component (1) which comprises at least one plastics layer (2) and at least one protection element (4, 7) which is connected to the plastics layer (2).

Description

[0001] Method for producing a hybrid component and pressing tool for producing a hybrid component

[0002] The present invention relates to a method for producing a hybrid component for traction battery housings or for a motor vehicle underbody protection by means of a pressing tool. Furthermore, the present invention relates to a pressing tool for producing a hybrid component.

[0003] Hybrid components are components that have at least two components or material components. For example, a hybrid component is a component with a plastic layer and a metal layer. It is known from the prior art to form a plastic component using, for example, an extrusion process, which, after its production, is joined to a metal component to reinforce the component, so that the finished component has a plastic layer and a metal layer.

[0004] A corresponding manufacturing process involves a large number of sequential work steps and is therefore complex in terms of spatial and temporal coordination.

[0005] In particular, in the case of large-area hybrid components such as components for a battery housing of a traction battery for electric vehicles (for example a battery housing lower shell, a battery housing upper shell or a battery housing cover) or an underbody protection for motor vehicles, the production of corresponding components is time-consuming and cost-intensive.

[0006] The present invention is based on the object of providing a method for producing a hybrid component by means of a pressing tool, by means of which stable and large-area hybrid components can be produced with reduced expenditure of time and at low cost.

[0007] The object underlying the present invention is achieved by a method for producing a hybrid component with at least one plastic layer and with at least one protective element connected thereto according to claim 1. Advantageous embodiments of the method are described in the claims dependent on claim 1.

[0008] More specifically, the object underlying the present invention is achieved by a method for producing a hybrid component which has at least one plastic layer and at least one protective element connected to the plastic layer, the method comprising the following method steps:

[0009] Providing a pressing tool having a lower tool part and an upper tool part, wherein the upper tool part and the lower tool part are movable relative to one another along a direction of movement or movement axis between an open position and a closed position of the pressing tool;

[0010] Placing at least one protective element and at least one plastic material in the press tool in the open position such that the plastic material and the protective element are arranged one above the other along the direction of movement; and

[0011] Closing the pressing tool, so that the upper tool part comes into contact at least indirectly with the at least one plastic or with the at least one protective element and the plastic is deformed by applying pressure by means of the upper tool part and / or by means of the lower tool part and the at least one plastic is connected to the at least one protective element to form the plastic layer.

[0012] The method according to the invention has the advantage that a hybrid component with increased stability can be manufactured using a tool-free process. Due to the tool-free production, the manufacturing costs of the hybrid part are significantly reduced, as is the manufacturing time.

[0013] The hybrid component is preferably designed as a hybrid component for a battery housing of a traction battery. For example, the hybrid component is designed as a battery housing and / or a battery housing lower shell and / or a battery housing upper shell and / or a battery housing cover and / or as an underbody protection.

[0014] The hybrid component is preferably designed as a hybrid component for underbody protection of a motor vehicle.

[0015] The lower tool part is preferably designed as a die. The upper tool part is preferably designed as a punch.

[0016] In the closed position of the pressing tool, the lower tool part and the upper tool part are spaced smaller apart than in the open position of the pressing tool.

[0017] The feature according to which the upper tool part comes into contact at least indirectly with the plasticized material when the pressing tool is closed means that the upper tool part comes into contact with the plasticized material either directly or by means of a further component (for example via a protective element). Preferably, two or more protective elements are placed in the pressing tool which is in the open position. Further preferably, the at least two protective elements are arranged next to one another with regard to the direction of movement of the upper tool part to the lower tool part. Further preferably, the at least two protective elements are connected to one another by the plastic layer of the hybrid component.A process designed in this way makes it possible to produce a hybrid component with increased thermal and mechanical resistance even in the case of complex geometric shapes of the hybrid component using a tool-free process and thus at a considerably lower cost and considerably faster.

[0018] Preferably, two or more plasticized parts are placed in the press tool in the open position. Furthermore, the at least two plasticized parts are preferably arranged next to one another with respect to the direction of movement of the upper tool part relative to the lower tool part. A method designed in this way allows a particularly large hybrid component to be manufactured off-the-tool.

[0019] The pressing tool can be designed as a plunge-edge tool. With a plunge-edge tool, the punch penetrates the die in the closed position of the plunge-edge tool in such a way that a substantially sealed space is created, with a gap of between 0.05 mm and 0.2 mm remaining between the punch and the die.

[0020] The plasticizer preferably comprises a matrix material and / or a fiber material. The matrix material can comprise or be formed from a polypropylene (PP) and / or a polyamide (PA) and / or another polymer. The fiber material can comprise or be formed from glass fibers and / or carbon fibers and / or aramid fibers. The plasticizer can be designed as a sheet molding compound (SMC) with glass fiber reinforcement or as a glass mat thermoplastic (GMT) comprising a glass fiber reinforced PP or as a direct long fiber thermoplastic (D-LFT) comprising a glass fiber reinforced PP and / or PA.

[0021] The at least one protective element preferably comprises a steel sheet and / or an aluminum sheet and / or an organic sheet. Further preferably, the at least one protective element is formed as a steel sheet, an aluminum sheet, or an organic sheet. The protective element preferably has a thickness in the range between 0.8 mm and 4 mm.

[0022] Organic sheets are fiber-matrix semi-finished products. These consist of a fiber fabric or fiber mesh embedded in a thermoplastic matrix. This improves hot formability and shortens production times. Furthermore, the flexural rigidity of the hybrid component can be improved.

[0023] Preferably, the plastic is connected to the at least one protective element in a form-fitting and / or material-fitting manner.

[0024] Further preferably, the method is designed such that the at least one protective element is deformed by exerting force by means of the at least one plastic.

[0025] Using the appropriately designed method, a hybrid component with even greater stability is produced, since the shape of the protective element increases the rigidity of the protective element and thus also the rigidity of the hybrid component. The hybrid component can still be produced off-tool, since the deformation of the protective element takes place during the process of joining the plastic to the protective element. Preferably, the lower tool part and / or the upper tool part has a shape to which the protective element adapts during its deformation.

[0026] The actual force is applied via the closing movement of the pressing tool. Due to the contact between the plastic and the protective element, the force required to deform the protective element is exerted or transmitted via the plastic.

[0027] Preferably, the lower tool part and / or the upper tool part has a shape which is designed such that the at least one protective element forms a flange when the at least one protective element adapts to the shape of the lower tool part and / or the upper tool part. In other words, the shaping of the lower tool part and / or the upper tool part can simultaneously achieve deep drawing of the protective element, so that a flange is formed. This allows a hybrid component with increased stability to be manufactured off-the-tool.

[0028] The flange can be designed as a circumferential wing flange. A circumferential wing flange allows a hybrid component to be more effectively connected to another component, such as a battery housing. At the same time, the stability of the hybrid component is increased.

[0029] The flange can have a width in the range between 8 mm and 25 mm, preferably in the range between 10 mm and 15 mm.

[0030] Preferably, the lower tool part and / or the upper tool part has a shape designed such that depressions and / or elevations are formed in the hybrid component and / or in the at least one protective element when the at least one protective element is deformed by exerting force using the at least one plastic. This allows an even more complex hybrid component to be manufactured off-tool. This is because the additional elevations and / or depressions can be produced during the process of joining the plastic to the protective element.

[0031] The recesses and / or elevations can be designed such that, for example, screw heads can be countersunk into the recesses and / or elevations. This allows the hybrid component to be more easily connected to another component, for example, a battery housing cover, by means of screws.

[0032] If the method is designed such that a first and a second protective element are introduced into the pressing tool and connected to the plastic material arranged between them by means of the pressing tool, the method can be designed such that the first protective element and the second protective element are deformed. Consequently, the method then comprises the following method step: deforming the first protective element and / or the second protective element by exerting force using the at least one plastic material. This allows a hybrid component with further improved stability to be manufactured off-the-tool.

[0033] Further preferably, the method is designed such that the at least one protective element is placed in the pressing tool in the open position such that the at least one protective element rests at least indirectly on the lower tool part and that the at least one plasticized material is placed on the at least one protective element. By means of the correspondingly designed method, the at least one protective element can be placed in the lower tool part with increased positioning accuracy, thus significantly improving the manufacturing accuracy of the hybrid component.

[0034] Preferably, the at least one protective element is placed on an ejection device of the pressing tool. The ejection device can be implemented, for example, in the form of ejection pins located in the lower tool part. After completion of the hybrid component, the ejection pins can be moved out of respective recesses in the lower tool part, whereby the finished hybrid component is ejected from the pressing tool.

[0035] The ejector pins can be designed as hydraulically controlled ejector pins. This allows the required demolding force to be individually adapted to the respective hybrid component, ensuring a uniform mechanical load is applied to the hybrid component during demolding.

[0036] The protective element can also be referred to as the first protective element.

[0037] Further preferably, the method is designed such that a second protective element is placed in the pressing tool in the open position such that the plasticized material is arranged between a first protective element, which rests at least indirectly on the lower tool part, and the second protective element. Furthermore, the pressing tool is closed so that the upper tool part comes into contact at least indirectly with the second protective element and the plasticized material is connected to the first protective element and the second protective element by pressure application by means of the upper tool part and / or by means of the lower tool part.

[0038] The correspondingly designed process enables the production of an even more stable hybrid component. This is because the correspondingly manufactured hybrid component has three layers, with the plastic layer sandwiched between the first protective element and the second protective element and connected to them.

[0039] The process also enables off-tool manufacturing of this more complex hybrid component. This significantly reduces production time and costs, even for this more complex hybrid component.

[0040] The second protective element can be inserted into the press tool in the open position such that the second protective element is arranged directly or indirectly on the upper tool part. Preferably, the second protective element can be arranged on the upper tool part magnetically and / or by suction using a vacuum. This allows the press tool to be closed immediately after the plasticized material has been placed, thus significantly shortening the production time of a hybrid component.

[0041] Further preferably, the method is designed in such a way that a pressing tool is provided which has a lower tool part and an upper tool part, wherein the upper tool part and the lower tool part are movable relative to one another along a direction of movement between an open position and a closed position of the pressing tool, and wherein a plurality of depressions are formed in the lower tool part and / or in the upper tool part and a plurality of ribs are formed from material of the plastic during the closing of the pressing tool by the material of the plastic being pressed into the depression.

[0042] The correspondingly designed process enables the off-tool production of a hybrid component with monolithic ribs. This process offers the advantage for this more complex hybrid component that the hybrid component can be manufactured at lower costs and with a reduced production time.

[0043] The ribs can be monolithically connected to the plastic layer.

[0044] Two monolithically connected components are made from a single, continuous piece. In particular, two monolithically connected parts are connected seamlessly.

[0045] Further preferably, the method is designed such that at least one protective element having a plurality of through openings and at least one plastic material are placed in the pressing tool in the open position such that the plastic material and the protective element are arranged one above the other along the direction of movement, and that the respective through openings are each aligned with the respective depressions so that the respective depressions are accessible via the respective through openings. A plurality of ribs are formed from material of the plastic material during the closing of the pressing tool by the material of the plastic material being pressed through the respective through openings into the respective depressions.

[0046] The correspondingly designed process enables the off-tool production of an even more stable hybrid component with monolithically formed ribs. This is because the correspondingly manufactured hybrid component has three layers, with the plastic layer sandwiched between the first protective element and the second protective element and connected to them, and the ribs monolithically connected to the plastic layer protruding through the through-openings of a protective element. This allows the production time and costs to be significantly reduced even for this even more complex hybrid component.

[0047] Further preferably, the method is designed such that the at least one protective element is heated before being brought into contact with the at least one plastic and / or before the pressing tool is closed.

[0048] The correspondingly designed method has the advantage that the plasticized material can flow more effectively on the protective element. This allows for a more uniform and thus improved bond between the protective element and the plasticized material, in particular between a protective element formed as a steel sheet and / or an aluminum sheet and the plasticized material.

[0049] The protective element can be heated, for example, by means of a convection oven, infrared radiation, induction or a heating plate.

[0050] Further preferably, the method is designed such that a contact surface of the at least one protective element, which is connected to the at least one plastic to form the plastic layer, is microstructured.

[0051] As a result, a micro-form fit can be achieved between the at least one protective element and the plasticized material when the pressing tool is closed. A micro-form fit within the meaning of the invention is understood to mean a form fit between two components, wherein one component is at least partially engaged by the other component at a plurality of points. This allows for an improved form fit with increased joining force. Furthermore, it allows for an improved connection between two components made of different materials, such as plastic and metal.

[0052] The microsurface structure of the contact surface of the at least one protective element is produced, for example, by means of a laser microstructuring process and / or by means of sandblasting or corundum blasting and / or by means of an etching process.

[0053] Further preferably, the method is designed in such a way that an adhesion promoter is applied to a contact surface of the at least one protective element, which is connected to the at least one plastic to form the plastic layer.

[0054] The adhesion promoter layer can achieve an improved connection, in particular an improved material-locking connection between the contact surface of the at least one protective element and the plastic layer.

[0055] The adhesion promoter layer can be formed as a heat-activatable adhesive layer, preferably in the form of a film, a lacquer, and / or a powder coating. The powder coating can be based on a thermoplastic or thermosetting material. This allows a further improved bond between the plastic and the at least one protective element to be achieved.

[0056] A further object underlying the present invention is to provide a pressing tool for producing a hybrid component, wherein the pressing tool enables a more cost-effective and faster production of a hybrid component with increased stability.

[0057] This object underlying the present invention is achieved by a pressing tool for producing a hybrid component having the features of claim 10. Advantageous embodiments are described in the claims dependent on claim 10.

[0058] More specifically, the object underlying the present invention is achieved by a pressing tool for producing a hybrid component, which has at least one plastic layer and at least one protective element connected to the plastic layer. The pressing tool has a lower tool part and an upper tool part, wherein the upper tool part and the lower tool part are movable relative to one another along a direction of movement between an open position and a closed position of the pressing tool. The pressing tool also has a holding device for holding the at least one protective element in the pressing tool.The pressing tool is designed so that when the pressing tool is transferred into its closed position, a plastic material introduced into the pressing tool and a protective element introduced into the pressing tool are pressed onto one another and connected to one another, wherein the plastic material introduced into the pressing tool is deformed to form the plastic layer.

[0059] The pressing tool according to the invention has the advantage that a hybrid component with increased stability can be produced off-the-tool. Due to off-the-tool production, the manufacturing costs of the hybrid part are significantly reduced, and at the same time, the manufacturing time is significantly reduced. The lower tool part is preferably designed as a die. The upper tool part is preferably designed as a punch.

[0060] The pressing tool can be designed as a plunge-edge tool. With a plunge-edge tool, the punch penetrates the die in the closed position of the plunge-edge tool in such a way that a substantially sealed space is created, with a gap of between 0.05 mm and 0.2 mm remaining between the punch and the die.

[0061] The pressing tool is preferably designed such that a plurality of recesses are formed in the lower tool part and / or in the upper tool part. The pressing tool is preferably designed such that, when the pressing tool is transferred into its closed position, the plastic material is pressed at least partially into the plurality of recesses, so that the plastic layer has a plurality of ribs monolithically connected to it.

[0062] The press tool designed in this way has the advantage that a more complex hybrid component with increased stability can be manufactured without the need for a separate tool. Due to the separate tool production, the manufacturing costs of the more complex hybrid part are significantly reduced, and at the same time, the manufacturing time is significantly shortened, even though the hybrid component is more complex to manufacture.

[0063] The pressing tool is preferably designed such that the pressing tool has an ejection device for ejecting the hybrid component. The ejection device is preferably designed to separate the hybrid component from the lower tool part and / or the upper tool part by applying force to the hybrid component after completion of the hybrid component. The pressing tool designed in this way has the advantage that the hybrid component can be manufactured as an off-the-tool component regardless of the geometric design. As a result, even with complex geometries of the hybrid component, the hybrid component can be manufactured with reduced manufacturing costs and reduced manufacturing time.

[0064] The ejection device can preferably be implemented in the form of ejection pins located in the lower tool part and / or in the upper tool part. After completion of the hybrid component, the ejection pins can be moved out of respective recesses in the lower tool part and / or in the upper tool part, whereby the finished hybrid component is ejected from the pressing tool.

[0065] The ejector pins can be designed as hydraulically controlled ejector pins. This allows the required demolding force to be individually adapted to the respective hybrid component, ensuring a uniform mechanical load is applied to the hybrid component during demolding.

[0066] The pressing tool is preferably designed such that the upper tool part and / or the lower tool part has a forming device for forming the at least one protective element. The pressing tool is preferably designed to deform the at least one protective element by applying force by means of the at least one plasticizing agent in the direction of the forming device during the closing movement of the pressing tool.

[0067] The press tool designed in this way has the advantage that a hybrid component with even greater stability can be produced, since the shape of the protective element increases the rigidity of the protective element and thus also the rigidity of the hybrid component. The hybrid component can still be manufactured off-tool, since the deformation of the protective element takes place during the bonding process of the plasticized material to the protective element.

[0068] Preferably, the forming device of the pressing tool is designed in such a way that the protective element adapts to the shape of the forming device when the protective element is deformed.

[0069] Preferably, the forming device of the pressing tool is designed such that the at least one protective element forms a flange when the at least one protective element adapts to the shape of the forming device of the pressing tool. In other words, the shaping of the forming device of the pressing tool can simultaneously deep-draw the protective element, so that a flange is formed. This allows a hybrid component with increased stability to be produced in a single manufacturing step.

[0070] The flange can be designed as a circumferential wing flange. A circumferential wing flange allows a hybrid component to be more effectively connected to another component, such as a battery housing cover. At the same time, the stability of the hybrid component is further increased.

[0071] The lower tool part and / or the upper tool part preferably has a shape which is designed such that depressions and / or elevations are formed in the hybrid component and / or in the at least one protective element when the at least one protective element is deformed by exerting force by means of the at least one plasticizer. This means that an even more complex hybrid component can be produced off-tool. This is because the additional elevations and / or depressions can be produced during the process of connecting the plasticizer to the protective element. The depressions and / or elevations can be designed such that, for example, screw heads can be countersunk in the depressions and / or elevations. This means that the hybrid component can be connected to another component, for example a battery housing cover, by means of screws in an improved manner.

[0072] The pressing tool is preferably designed such that the pressing tool has a hold-down device attached to the lower tool part, which can be moved in the direction of movement between a first position and a second position. In the first position, the at least one protective element can be clamped between the hold-down device and the upper tool part, and in the second position, the at least one protective element is arranged loosely between the hold-down device and the upper tool part with respect to the direction of movement. The pressing tool is designed to hold the at least one protective element clamped between the hold-down device in the first position and the upper tool part during the closing movement. Furthermore, the pressing tool is designed to deform the at least one protective element by applying force by means of the at least one plasticizer during the closing movement of the pressing tool.

[0073] The pressing tool designed in this way has the advantage that a hybrid component with even better stability and increased quality can be produced. By means of the hold-down device, a uniform flow process of the protective element can be achieved during the deformation of the at least one protective element and in particular the formation of folds in the vicinity of the flow zone of the at least one protective element can be avoided. As a result, high degrees of deformation can also be achieved with consistent quality of the hybrid component. The feature that the at least one protective element is arranged loosely with respect to the direction of movement between the hold-down device and the upper tool part in the second position of the hold-down device can also be expressed in such a way that the at least one protective element is not clamped between the hold-down device and the upper tool part in the second position of the hold-down device.

[0074] The first position of the hold-down device is preferably reached during the closing movement of the pressing tool, before the closing position of the pressing tool. As a result, the at least one protective element is clamped between the hold-down device and the upper tool part before the at least one protective element is deformed.

[0075] The second position of the hold-down device is preferably reached during the opening movement of the pressing tool, before the pressing tool is in the open position. This allows the hybrid component to be ejected more quickly after completion.

[0076] The hold-down device can have a spring bearing. This allows for improved adjustment of the clamping force during deformation of the at least one protective element.

[0077] The spring bearing can be hydraulic, mechanical or pneumatic.

[0078] The pressing tool is preferably designed such that the upper tool part has a holding device for holding the at least one protective element in the pressing tool. The holding device is preferably designed as a magnetic holding device or as a holding device that generates a negative pressure. The pressing tool designed in this way has the advantage that the pressing tool can be closed immediately after the plastic material has been placed. This can significantly shorten the production time of a hybrid component.

[0079] The magnetic holding device can be designed as a magnetic ejector pin. In other words, an ejector pin can simultaneously be a magnetic holding device. Through this functional integration, a press tool can be manufactured at a lower cost, which in turn allows a hybrid component to be manufactured at a lower cost.

[0080] The holding device that generates a negative pressure can be designed as an ejector pin that generates a negative pressure. In other words, an ejector pin can simultaneously be a holding device that generates a negative pressure. Through this functional integration, a pressing tool can be manufactured at a lower cost, which in turn allows a hybrid component to be manufactured at a lower cost.

[0081] Further advantages, details and features of the invention will become apparent from the following exemplary embodiments. These show in detail:

[0082] Figure 1A: a schematic sectional view of a pressing tool according to the invention according to a first embodiment in an open position;

[0083] Figure 1B: a schematic sectional view of the pressing tool shown in Figure 1A after completion of a hybrid component in an opening movement according to

[0084] Leaving a closed position of the pressing tool; Figure 2A: a schematic sectional view of a pressing tool according to the invention according to a second embodiment in an open position;

[0085] Figure 2B: a schematic sectional view of the pressing tool shown in Figure 2A after completion of a hybrid component in an opening movement after leaving a closed position of the pressing tool;

[0086] Figure 3A: a schematic sectional view of a pressing tool according to the invention according to a third embodiment in an open position;

[0087] Figure 3B: a schematic sectional view of the pressing tool shown in Figure 3A after completion of a hybrid component in an opening movement after leaving a closed position of the pressing tool;

[0088] Figure 4A: a schematic sectional view of a pressing tool according to the invention according to a fourth embodiment in a first position of a holding-down device; and

[0089] Figure 4B: a schematic sectional view of the pressing tool shown in Figure 4A, wherein the hold-down device is in a second position.

[0090] In the following description, the same reference numerals designate the same components or the same features, so that a description given with respect to one figure regarding a component also applies to the other figures, thus avoiding a repetitive description. Furthermore, individual features that were described in connection with one embodiment can also be used separately in other embodiments. A method for producing a hybrid component 1 is explained using the pressing tool 10 shown in Figures 1A and 1B. Figure 1A shows a schematic sectional view of a pressing tool 10 for producing a hybrid component

[0091] 1 in an open position according to a first embodiment of the present invention. The pressing tool 10 has a lower tool part 20 and an upper tool part 30, wherein the lower tool part 20 and the upper tool part 30 are movable relative to one another along a direction of movement R between an open position and a closed position of the pressing tool 10. The pressing tool 10 also has a holding device 21 for holding the at least one protective element 4 in the pressing tool 10.

[0092] In an open position of the pressing tool 10 shown in Figure 1A, at least one protective element 4 and at least one plastic P are placed in the pressing tool 10 such that the plastic P and the protective element 4 are arranged one above the other along the direction of movement R.

[0093] The protective element 4 is placed in the press tool 10 in the open position such that the protective element 4 rests at least indirectly on the lower tool part 20. The plastic P is placed on the protective element 4.

[0094] The pressing tool 10 is designed so that when the pressing tool 10 is transferred into its closed position, the plastic P introduced into the pressing tool 10 and the protective element 4 introduced into the pressing tool 10 are pressed onto one another and connected to one another, wherein the plastic P introduced into the pressing tool 10 is pressed onto the other and forms a plastic layer.

[0095] 2 of the hybrid component 1 shown in Figure 1B is deformed. The hybrid component 1 produced in this way thus has at least one plastic layer 2 and at least one protective element 4 connected to the plastic layer 2.

[0096] Figure 1B shows a schematic sectional view of a pressing tool 10 for producing a hybrid component 1 in an opening movement after completion of the hybrid component 1 after leaving a closed position according to the first embodiment of the present invention.

[0097] A plurality of recesses 33 are formed in the upper tool part 30. The pressing tool 10 is designed such that, when the pressing tool 10 is transferred into its closed position, the plastic P is pressed at least partially into the plurality of recesses 33, so that the plastic layer 2 has a plurality of ribs 3 monolithically connected thereto.

[0098] The hybrid component 1 produced in this way consequently has at least one plastic layer 2 and at least one protective element 4 connected to the plastic layer 2, wherein the plastic layer 2 has a plurality of ribs 3 monolithically connected to the plastic layer 2.

[0099] The pressing tool 10 has an ejection device 24 for ejecting the hybrid component 1, wherein the ejection device 24 is designed to separate the hybrid component 1 from the lower tool part 20 and / or the upper tool part 30 after completion of the hybrid component 1 by applying force to the hybrid component 1.

[0100] The ejection device 24 is implemented in the form of ejector pins 24 located in the lower tool part and in the upper tool part. The ejector pins 24, which are arranged in the upper tool part 30, are aligned with a plurality of recesses 33, so that after completion of the hybrid component 1, the hybrid component 1 can be separated from the upper tool part 30 by applying force to a plurality of ribs 3 of the hybrid component 1.

[0101] Figures 2A and 2B show a pressing tool 10 according to a second embodiment of the present invention, wherein in Figure 2A the pressing tool 10 is shown in an open position and in Figure 2B in an opening movement after leaving a closed position. The manufacturing process of a further hybrid component 1 is explained using the pressing tool 10 shown in Figures 2A and 2B.

[0102] The lower tool part 20 of the pressing tool 10 shown in Figure 2A has a forming device 32 for forming the protective element 4. The pressing tool 10 is designed to deform the protective element 4 by applying force by means of the plastic P in the direction of the forming device 32 during the closing movement of the pressing tool 10.

[0103] The hybrid component 1 produced by a pressing tool 10 according to the second embodiment has a protective layer 4 which has been adapted to the shape of the forming device 32 of the lower tool part 20.

[0104] In Figures 2A and 2B, it is not shown that the pressing tool 10 has an ejection device. However, the pressing tool 10 according to the second embodiment can also have an ejection device 24. With regard to the design of the ejection device 24, reference is made to the above description with reference to Figures 1A and 1B. The remaining structure of the pressing train 10 according to the second embodiment corresponds to the structure of the pressing tool 10 according to the first embodiment, so that reference is made to the above explanations to avoid repetition.

[0105] Figures 3A and 3B show a schematic cross-sectional view of a pressing tool 10 according to a third embodiment. The manufacturing process of a hybrid component 1 is explained using the pressing tool 10 shown in Figures 3A and 3B.

[0106] The upper tool part 30 of the pressing tool 10 has a holding device 34 for holding a second protective element 7 in the pressing tool 10. The holding device 34 can be designed as a magnetic holding device 34 or as a holding device 34 generating a negative pressure.

[0107] In an open position of the pressing tool 10, the second protective element 7 is placed in the pressing tool 10 such that the plastic P is arranged between the first protective element 4, which rests on the lower tool part 20, and the second protective element 7.

[0108] Subsequently, the pressing tool 10 is closed so that the plastic P is connected to the first protective element 4 and the second protective element 7 by applying pressure by means of the upper tool part 30 and / or by means of the lower tool part 20.

[0109] The first protective element 4 has a plurality of through openings 6. The plastic P and the first protective element 4 are placed in the pressing tool 10 in the open position such that the plastic P and the protective element 4 are arranged one above the other along the direction of movement R, and that the respective through openings 6 are each aligned with the respective recesses 33, so that the respective recesses 33 are accessible via the respective through openings 6.

[0110] Figure 3B shows a schematic sectional view of the pressing tool 10 shown in Figure 3A after completion of the hybrid component 1 in an opening movement after leaving a closed position.

[0111] During the closing of the pressing tool 10, the ribs 3 are formed from the material of the plastic P by pressing the material of the plastic P through the respective through openings 6 into the respective recesses 23.

[0112] Figures 4A and 4B show a schematic sectional view of a pressing tool 10 according to a fourth embodiment of the present invention, on the basis of which the production process of a further hybrid component 1 is explained. Figure 4A shows a schematic sectional view of a pressing tool 10 for producing a hybrid component 1 in a first position of a hold-down device according to a fourth embodiment of the present invention. The pressing tool 10 has a hold-down device 40 attached to the lower tool part 20, which can be moved in the direction of movement R between a first position and a second position.

[0113] In the first position of the hold-down device 40, the at least one protective element 7 is clamped between the hold-down device 40 and the upper tool part 30.

[0114] The first position of the hold-down device 40 is reached during the closing movement of the pressing tool 10, before the closing position of the pressing tool 10. As a result, the at least one protective element 7 is clamped between the hold-down device 40 and the upper tool part 30 before the at least one protective element 7 is deformed.

[0115] The pressing tool 10 is designed to hold the at least one protective element 7 clamped between the hold-down device 40 in the first position and the upper tool part 30 during the closing movement and to deform the at least one protective element 7 by applying force by means of the at least one plastic material P during the closing movement of the pressing tool 10.

[0116] The hold-down device 40 has a spring bearing 41 by means of which the clamping force can be adjusted during the deformation of the protective element 7.

[0117] Figure 4B shows a schematic sectional view of a pressing tool 10 for producing a hybrid component 1 in a second position of the hold-down device 40 according to the fourth embodiment of the present invention.

[0118] In the second position, the at least one protective element 7 is loosely arranged between the hold-down device 40 and the upper tool part 30 with respect to the direction of movement R.

[0119] The second position of the hold-down device 40 is reached during the opening movement of the pressing tool 10 before the open position of the pressing tool 10. This allows the hybrid component 1 to be ejected more quickly after completion. List of reference symbols

[0120] 1 hybrid component

[0121] 2 plastic layers (of the hybrid component)

[0122] 3 ribs (the plastic would be)

[0123] 4 (first) protective element (of the hybrid component)

[0124] 5 Contact surface (of the first protective element)

[0125] 6 Through opening (of the protective element)

[0126] 7 (second) protective element (of the hybrid component)

[0127] 8 Contact surface (of the second protective element)

[0128] 10 Press tool

[0129] 20 Lower tool part (of the pressing tool)

[0130] 21 Holding device (of the lower tool part)

[0131] 22 Forming device (of the lower tool part)

[0132] 23 Recess (of the lower tool part)

[0133] 24 Ejector device / ejector pins (of the lower tool part)

[0134] 30 Upper tool part (of the pressing tool)

[0135] 32 Forming device (of the upper tool part)

[0136] 33 Recess (of the upper tool part)

[0137] 34 Holding device (of the upper tool part)

[0138] 40 Hold-down device / holding device

[0139] 41 Spring bearing (of the hold-down device)

[0140] P Plastif ikat

[0141] R Direction of movement (of the upper tool part with respect to the lower tool part)

Claims

Patent claims 1. A method for producing a hybrid component (1) which has at least one plastic layer (2) and at least one protective element (4, 7) connected to the plastic layer (2), the method comprising the following method steps: Providing a pressing tool (10) having a lower tool part (20) and an upper tool part (30), wherein the upper tool part (30) and the lower tool part (20) are movable relative to one another along a direction of movement (R) between an open position and a closed position of the pressing tool (10); Placing at least one protective element (4, 7) and at least one plasticized product (P) into the pressing tool in the open position such that the plasticized product (P) and the protective element (4, 7) are arranged one above the other along the direction of movement (R); and closing the pressing tool (10) so that the upper tool part (30) comes into contact at least indirectly with the at least one plasticized product (P) or with the at least one protective element (4, 7) and the plasticized product (P) is deformed by applying pressure by means of the upper tool part (30) and / or by means of the lower tool part (20), and the at least one plasticized product (P) is connected to the at least one protective element (4, 7) to form the plastic layer (2).

2. Method according to claim 1, characterized by the following method step: Deforming the at least one protective element (4, 7) by exerting force by means of the at least one plastic (P).

3. Method according to one of the preceding claims, characterized by the following method steps: Placing the at least one protective element (4) into the pressing tool (10) in the open position such that the at least one protective element (4) rests at least indirectly on the lower tool part (20); and placing the at least one plasticized material (P) on the at least one protective element (4).

4. Method according to claim 3, characterized by the following features: Placing a second protective element (7) in the pressing tool (10) in the open position such that the plasticized material (P) is arranged between a first protective element (4), which rests at least indirectly on the lower tool part (20), and the second protective element (7); and closing the pressing tool (10) such that the upper tool part (30) comes into contact at least indirectly with the second protective element (7) and the plasticized material (P) is connected to the first protective element (4) and the second protective element (7) by applying pressure by means of the upper tool part (30) and / or by means of the lower tool part (20).

5. Method according to one of the preceding claims, characterized by the following method steps: Providing a pressing tool (10) comprising a lower tool part (20) and an upper tool part (30) wherein the upper tool part (30) and the lower tool part (20) are movable relative to one another along a direction of movement (R) between an open position and a closed position of the pressing tool (10), and wherein a plurality of recesses (23, 33) are formed in the lower tool part (20) and / or in the upper tool part (30); and forming a plurality of ribs (3) from material of the plasticized material (P) during the closing of the pressing tool (10) by pressing the material of the plasticized material (P) into the recesses (23, 33).

6. Method according to claim 5, characterized by the following features: Placing at least one protective element (4, 7) having a plurality of through-openings (6) and the at least one plasticized material (P) into the pressing tool (10) in the open position such that the plasticized material (P) and the protective element (4, 7) are arranged one above the other along the direction of movement (R), and such that the respective through-openings (6) are each aligned with the respective recesses (23, 33) such that the respective recesses (23, 33) are accessible via the respective through-openings (6); and forming a plurality of ribs (3) from material of the plasticized material (P) while the pressing tool (10) is closing, by pressing the material of the plasticized material (P) through the respective through-openings (6) into the respective recesses (23, 33). Method according to one of the preceding claims, characterized by the following feature: Heating the at least one protective element (4, 7) before bringing it into contact with the at least one plastic material (P) and / or before closing the pressing tool (10).

8. Method according to one of the preceding claims, characterized by the following feature: Microstructuring a contact surface (5, 8) of the at least one protective element (4, 7), which is connected to the at least one plasticized material (P) to form the plastic layer (2).

9. Method according to one of the preceding claims, characterized by the following feature: Applying an adhesion promoter to a contact surface of the at least one protective element (4, 7), which is connected to the at least one plasticized material (P) to form the plastic layer (2).

10. Pressing tool (10) for producing a hybrid component (1) which has at least one plastic layer (2) and at least one protective element (4, 7) connected to the plastic layer (2), wherein the pressing tool (10) has the following features: the pressing tool (10) has a lower tool part (20) and an upper tool part (30); the upper tool part (30) and the lower tool part (20) are movable relative to one another along a direction of movement (R) between an open position and a closed position of the pressing tool (10); the pressing tool (10) has a holding device (21, 34, 40) for holding the at least one protective element (4, 7) in the pressing tool (10); and the pressing tool (10) is designed such that, when the pressing tool (10) is transferred into its closed position, a plasticized material (P) introduced into the pressing tool (10) and a protective element (4, 7) introduced into the pressing tool (10) are pressed onto one another and connected to one another, wherein the plasticized material (P) introduced into the pressing tool (10) is deformed to form the plastic layer (2).

11. Press tool (10) according to claim 10, characterized by the following features: a plurality of recesses (23, 33) are formed in the lower tool part (20) and / or in the upper tool part (30); and the press tool (10) is designed such that, when the press tool (10) is transferred into its closed position, the plasticized material (P) is pressed at least partially into the plurality of recesses (23, 33), so that the plastic layer (2) has a plurality of ribs (3) monolithically connected to it.

12. Press tool (10) according to claim 10 or 11, characterized by the following features: the press tool (10) has an ejection device (24) for ejecting the hybrid component (1); and the ejection device (24) is designed to separate the hybrid component (1) from the lower tool part (20) and / or the upper tool part (30) after completion of the hybrid component (1) by applying force to the hybrid component (1).

13. Press tool (10) according to one of claims 10 to 12, characterized by the following features: the upper tool part (30) and / or the lower tool part (20) has a forming device (32) for forming the at least one protective element (4, 7); and the pressing tool (10) is designed to deform the at least one protective element (4, 7) by applying force by means of the at least one plasticized material (P) in the direction of the forming device (32) during the closing movement of the pressing tool (10).

14. Press tool (10) according to one of claims 10 to 13, characterized by the following features: the press tool (10) has a hold-down device (40) attached to the lower tool part (20), which is movable in the direction of movement (R) between a first position and a second position; in the first position, the at least one protective element (4, 7) can be clamped between the hold-down device (40) and the upper tool part (30); in the second position, the at least one protective element (4, 7) is freely movable between the hold-down device (40) and the upper tool part (30) with respect to the direction of movement (R); the press tool (10) is designed to hold the at least one protective element (4, 7) clamped firmly between the hold-down device (40) in the first position and the upper tool part (30) during the closing movement;and the pressing tool (10) is designed to deform the at least one protective element (4, 7) by applying force by means of the at least one plasticized material (P) during the closing movement of the pressing tool (10); 15. Press tool (10) according to one of claims 10 to 14, characterized by the following features: the upper tool part (30) has a holding device (34) for holding the at least one protective element (4, 7) in the press tool (10); and the holding device (34) is designed as a magnetic holding device (34) or as a holding device (34) generating a negative pressure.

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